Process Control Systems Design and Engineering Projects
Control Innovations have successfully completed projects for many
internationally recognised blue chip companies around the world. These projects have included the following
Dyson – Singapore
This project consisted of the Electrical Design, Control Panel Build, Installation and Commissioning of four
assembly lines and four end of line test machines producing motors for the range of Dyson products including vacuum
cleaners and the airblade hand dryer. All of the lines and end of line machines were fully tested in the UK before
being installed and commissioned in Singapore by Control Innovations UK staff. The control systems consisted of
Omron CPM2 and CJ1M PLC’s and NT and NS HMI’s with an Ethernet networks to allow for PLC to PLC communication.
Nestle – Switzerland
This project utilised Beckhoff’s TwinCat system to provide visualisation and control of four Ishida weighers on a
Modbus TCP/IP network. The system allowed for full operator control of the four Weigers and also modification of
recipe data. A complete recipe consisting of 500 Modbus registers can be copied from one Weigher to any or all of
the other three Weighers. The system was commissioned in Germany.
Federal Mogul – Chapel-en-le-Frith
Two machines were designed and built to carry out the final assembly operations for Ferrodo brake pads. The
machines were controlled by Allen Bradley SLC5/05 PLC’s and Panelviews. All the field I/O was on ASI which allowed
for the machine to be quickly stripped for shipping and then quickly reassembled and put into production on the
customer site. Control Innovations carried out the Electrical Design, Control Panel Build, Installation and
Commissioning both at the machine builders site and at Federal Mogul.
Snellman – Finland
Two S7-300 PLC systems were used to control the tray sealing of packed meat products on the production floor and
also for the supply of empty trays, not only to the new production line but also to the existing production lines.
The first system had a single Siemens touchscreen HMI while the second system had 2 x Siemens touchscreen HMI’s.
Both PLC’s included Ethernet communications to the main plant production scheduling system. Control Innovations
carried out the Electrical Design and Control Panel Build followed by the Installation and Commissioning in
Novatis – Liverpool
A Siemens S7-300 PLC and TP377 HMI were used to control a NF Filtration system used to treat the waste product from
producing flu vaccines including bird and swine flu. The pumps on this project were controls by Siemens Micromaster
drives which were connected to the PLC and controlled on a Profibus network. On this project Control Innovation
also supplied all the pneumatic valves and pneumatic installation. Control Innovations carried out the Electrical
Design and Control Panel Build followed by the Installation and Commissioning in Liverpool.